So you're looking to create a piece that slides in snug to the aquarium with a bottom, back, sides and I guess the front in 2 pieces? - Just trying to picture things.
Sounds quite brave!
I'm unsure quite how it would work but if the silicone joints were sealed off from the foam then you would be able to make it in situ and then when the time comes tear it out and carefully scrape it all from the glass with a clean blade.
You could possibly cover the parts where foam touches the glass in vinyl so you don't see it- printed vinyl even if you can either find something or get something printed.
No, not quite Andrew - it's hard to describe in words. Say you have a EA Aquascaper 900, and you want to make a bank style background to the rear and left side. So, internally the rear pane is around 880 x 440 internally. So my plan would be cut a piece of clear (or maybe black) perspex to maybe 875 x 435, perhaps with a 100mm flange/bend on the base to help it stand and distribute the weight (this would be covered by substrate anyway).
I would then lay it flat on its back whist constructing the 'bank'. Rough sand it for a good key to the expanding foam, add a layer of the expanding foam a section at a time, and press the lava rock into it. Carve the excess and decorate as detailed above.
Then once dried, completed and washed, I'd stand the whole thing up on that 100mm flange, and on the rear add a very small very thin and continuous bead of silicone to around all four edges about 25mm in from the edges.
I'd possibly lay the aquarium on its back, and then lower the 'river bank' background into the tank so the silicone bead forms a seal with the rear glass panel of the tank. Once dried stand the tank back up. Repeat for the side panel - obviously the design of the 'bank', and the flange on the base would need to account for the join/transitions between the side and rear.
Only thing that might be cause for concern is the weight perhaps.
Hopefully the thin bead of silicone would prevent water ingress behind the pre-fab backgrounds, and mean to remove them is a matter of slitting that thin silicone bead, and then removing from the tank inner panes in the usual ways.
Does that make sense? This is all just theory of course at this stage. I will no doubt hit stumbling blocks if/when I attempt it for real, and have to figure out work arounds. In the meantime, I have ordered a few bits to attempt a mini mock up to test the theory.